MECHANICAL CONDITION MONITORING ON ROTARY KILNS. Measurement Tools for the Cement Industry

Transcription

1 MECHANICAL CONDITION MONITORING ON ROTARY KILNS Measurement Tools for the Cement Industry

2 Agenda About TomTom-Tools GmbH New Kiln Axis Alignment System Tablet PC with Long Range Bluetooth Ovality Sensor Inductive Distance Measurement (IDM) Tool Kit Gear Run-Out Measurement Roller Shaft Bending Measurement Mechanical Kiln Monitoring (MKM) System Measuring Wheel Rotary Inclinometer Kiln Shell Laser + Rotation Trigger Telescopic Contact Thermometer

3 About TomTom-Tools GmbH Founded in 2007, the tools are now already in about 50 countries in use TomTom-Tools GmbH Zelgli 20, 8905 Arni Switzerland tomtom-tools.com Head Quarter: Branch: Team: Arni, Switzerland Curitiba, Brazil 5 engineers, 2 technicians, 3 in administration

4 New fast and precise system to measure the kiln axis by using a target axle and a laser theodolite Target Axle with Reflector Prism Reference point for stationing Calculated kiln center Robotic Total Station Leica TS60 or MS60 Later also from Trimble

5 Kiln Axis Measurement System Overview Typically 2 stationing of theodolite are sufficient Calculated kiln center Reference point for stationing Assistant with Target Axle Main Operator with Robotic Total Station

6 The ball reflectors make the measurement easy, precise and fast Target Axle on kiln tire The target catching function of the theodolite find and measure the targets quickly. It does not require precise targeting by the operator Reference point distributed around the kiln for re-stationing of theodolite Target on shaft center with Rotation Adapter

7 The results of the measurement is the value how much to move the rollers to get the kiln straight Kiln Axis deviation: Expected center determination accuracy: +/- 1mm (depending on accuracy of laser theodolite) Side View Top View

8 The new method for kiln axis measurement brings several advantages Independent if kiln is in operation or stopped Easy to measure no specialized geo surveying knowledge required 1 2 days training is sufficient Low number of sources for errors The operators are in contact via the hand free intercom Fast A kiln with 3 piers can be measured easily within halve a day, traditional methods require up to several days Diameter of rollers and tires have not to be measured Typically only two positions of theodolite are required Easy to analyze The results are immediately visible in the PC Possible erroneous measurements can be repeated at the spot No transfer to other software required Unmistakable visualization in 3D The data can easily be shared and distributed via

9 Kiln Axis Alignment Accessory Kit, includes all special components to measure the kiln axis Magnetic Base for Reference Points Radio Intercom Shaft Center Adapter Long Range Bluetooth Adapter (USB) Communication Headset Target Axle Rotation Adapter Magnetic Reflector Holder

10 Some impressions from the measurement

11 Example: Kiln axis alignment measurement, correction and confirmation Day 1: Measurement of kiln axis Deviation detected (Tire 2: 4mm left, 7mm down) Recommended correction: move left roller of pier 2 by 8mm towards kiln center Day 2: Performed Correction: Left roller of pier 2 was moved by 6.7mm towards kiln center The kiln axis was measured again and found well within tolerance 11

12 Industrial Tablet PC, Panasonic TOUGHPAD FZ-G1 with Long Range Bluetooth The special TomTom Bluetooth Adapter makes the Tablet PC to match perfectly to the kiln measurement tools

13 Ovality on Kiln Shell, Focus Areas Deformation at Rollers Deformation on Top Ovality Sensor

14 Ovality Sensor On YouTube Ovality Sensor

15 Ovality Sensor Working Principle S+ P- P+ S- Ovality Sensor

16 Ovality Sensor The Ovality Sensor is a measurement tool for rotary kilns, which measures the changes of the roundness / curvature in the kiln shell during operation. This elastic deformation is called Ovality and is primarily present in the area of a kiln tire. The measurement gives accurate information about the degree of mechanical loads in the refractory / kiln shell and allows defining the countermeasures in advance to increase the lifetime of the kiln components. Ovality Sensor

17 Measurement Positions Along the Kiln The Ovality typically is measured at 3 positions on both sides of each tire A C The position A typically is in line with the reference of the kiln, often the manhole is used as reference The Ovality Sensor should be placed close to the tire, where the ovality is the highest B Make sure the contact surface is clean enough that the magnets are able to keep the tool in position Ovality Sensor

18 Measurement Studio / Ovality Radar Chart Main Function Buttons Kiln Overview Ovality Sensor Measurement Results

19 Correct Shimming of the Tire is the Key Too thick shims can lock the tire Shell constriction Too thin shims increase the ovality Brick failures Ovality Sensor

20 Inductive Distance Measurement (IDM) Tool Kit The IDM Tool Kit is a multi purpose measurement tool. Typically it is used to check the condition of rotating parts during operation (e.g. on Rotary Kilns, Dryers, Ball Mills). It measures variation of distances of moving metal surfaces without contact with high accuracy and high speed. It can be considered as a contactless dial gauge IDM Tool Kit, Gear Run-Out

21 Inductive Distance Measurement (IDM) Tool Kit IDM Tool Kit, Gear Run-Out

22 National Instrument Hi-Speed USB Carrier NI USB-9162 National Instrument NI crio /- 10VDC IDM Controller Schematic LED 24VDC USB 24 VDC 100 ma - + COM NC AI 7 AI 6 AI 5 AI 4 AI 3 AI 2 AI 1 AI brown (+) 2 white (0-10V) 3 blue (-) 4 black (n.a.) Inductive Sensor + U - 1 IDM Tool Kit

23 Different Inductive Sensor Types 1 brown (+) 2 white (0-10V) 3 blue (-) 4 black (n.a.) 1 brown (+) 2 white (0-20mA) 3 blue (-) 4 black (n.a.) 1 brown (+) 2 white (0-20mA) 3 blue (-) 4 black (0-10V) 1 brown (+) 2 white (24V) 3 blue (-) 4 black (n.a.) Inductive Distance Sensor (Output 0-10V) + U - Inductive Distance Sensor (Output 0-20mA) + I - Inductive Distance Sensor (Output 0-20mA, 0-10V) + I - U Inductive Proximity Switch (Output = Input) + U - IDM Tool Kit Voltage Signal (used in IDM Tool): Simple to measure Used for short distances Disturbed by other electrical fields Milliampere Signal (used in MKM System): Used for long distances Stable signal No disturbed by other electrical fields Combined Sensor Can be used for both abovementioned applications Sensor is used as Switch Gives signal, when metal is detected Output signal in Volt (same as Input, typically 24V)

24 Run-Out Measurement of Girth Gear The measured values are not affected by oil, grease or dust Continuous as well as interrupted surfaces can be measured (Note: Sampling rate has to be adjusted according to rpm and surface type) Kiln Girth Gear Inductive Sensor Axial Sensor (on side face) Magnet Stand IDM Controller IDM Tool Kit, Gear Run-Out On YouTube Radial Sensor (on tooth tip) Magnet Stand

25 Line Chart: Axial + Radial Values Measured Values Remarks Calculated Results IDM Tool Kit, Gear Run-Out

26 Radar Chart: Radial Values Centre of rotation Ideal Circle (with eccentricity) Centre of Girth Gear Remarks Measured Values Calculated Results IDM Tool Kit, Gear Run-Out

27 a x i a l r a d i a l Run-Out Definition Eccentricity & Roundness Deviation Total Run-Out a a Wobbling & Straightness Deviation Total Run-Out IDM Tool Kit, Gear Run-Out

28 T=250 C Uneven Shell Temperature Thermal Crank Big temperature variation around circumference C Reduced Load IDM Tool Kit, Roller Shaft Bending

29 Crank In Tire Area (up) High Load No Load High Load IDM Tool Kit, Roller Shaft Bending

30 Crank In Tire Area (down) Reduced Load High Load Reduced Load IDM Tool Kit, Roller Shaft Bending

31 IDM Tool Kit makes crank visible High load on roller No or low load on Roller Inductive Distance Sensor Roller Shaft Bending

32 Roller Bending Measurement The roller shaft bending is measured via the radial displacement of the roller surface (run-out) The sensor is located in the line of force under the roller It is measured during normal operation (no stop required) Only the variations are measured due to a crank, the static load due to weight and possible alignment errors are not measured Inductive Distance Sensor Roller Shaft Bending

33 Thermal Crank (example 3 station kiln) July 13: strong thermal crank high variation in roller shaft bending (±0.3mm) July 15: no thermal crank low roller shaft bending value (±0.08mm)

34 Roller Shaft Bending Measurement On YouTube IDM Tool Kit, Roller Shaft Bending

35 Measurement Studio / Roller Shaft Bending Roller Shaft Bending Curve Reference Line (each kiln revolution) Roller Shaft Bending Value Position of Crank IDM Tool Kit, Roller Shaft Bending

36 MKM-System (Mechanical Kiln Monitoring System) Sensors for: 1. Roller Shaft Bending Measurement 2. Rotation Indication 3. Relative Movement of Tires 4. Axial Kiln Position 1 3 MKM System

37 MKM-System (Mechanical Kiln Monitoring System) 2. Rotation Indication 4. Axial Kiln Position 1. Roller Shaft Bending 3. Rel. Movement of Tire MKM System

38 Tire 3 Tire 2 Tire 1 MKM-System (Mechanical Kiln Monitoring System) Material Flow B3.3 B3.2 B4.2 B4.1 B3.1 B2.1 B1.3 B1.2 B1.1 Power Supply VAC MKM Control Box 1. Roller Shaft Bending Measurement Signal Outputs mA 4. Axial Kiln Position Measurement 3. Relative Tire Movement Measurement MKM System

39 MKM Sensor Installation Kiln Speed Sensor Axial Kiln Position Sensor MKM System Axial Kiln Position Sensor Roller Shaft Bending Sensor Relative Tire Movement Sensor

40 MKM Controller / Data Logger LED Terminal Block for Sensor and Output Signals Data Logger (DALOG 376) SD Card Reader Power supply VAC 24VDC Terminal Block Sensors Power Supply MKM System

41 Measuring Wheel The Measuring Wheel is a measurement tool, which measures the diameter of slow rotating cylinders during operation; for example on support rollers or tires on rotary kilns or dryers. These components are typically subject to a certain amount of wear and have to be re-machined or replaced after some time of operation In order keep the kiln or drier axis aligned; it is essential to know the changes of the diameters and to compensate them by adjusting the roller positions Measuring Wheel

42 Measuring Wheel Measuring Wheel

43 Measuring Wheel Schematic Light Barrier Sensor (heat resistant 180 C) Diameter to measure Measuring Wheel with Encoder Magnetic Switch Flag Light Converter Spring Loaded Wheel Suspension Wheel Controller Measuring Wheel

44 Measuring Wheel On YouTube Measuring Wheel

45 Measurement of Cylindricity Measuring Wheel

46 Rotary Inclinometer The Rotary Inclinometer is a measurement tool, which measures the axle inclinations of slow rotating parts during operation (e.g. Rotary Kilns, Dryers, Ball Mills in barring mode). It measures deviations in vertical direction with a high accuracy, which makes the alignment work much easier. It can be considered as a water level for slow rotating parts. Rotary Inclinometer

47 Rotary Inclinometer Inclinometer with heat shield to measure hot kiln tires Inclinometer with shaft adapter to measure support rollers at the shaft center Rotary Inclinometer

48 Rotary Inclinometer Schematic Magnet Linear Motion Module X Gimbal-mounted Inclination Sensor ( ) Linear Motion Module Y Status LED Rotation Sensor Circuit Board Rechargeable Li-Ion Battery Rotary Inclinometer

49 Roller Inclination Measurement On YouTube Rotary Inclinometer

50 Measurement Studio: Inclination Measured Values Inclination Values per Revolution Remarks Calculated Results

51 Kiln Shell Laser The Kiln Shell Laser is a measurement tool, which measures the deformations (roundness, straightness, eccentricity) in shells of rotary kiln and dryer during operation. Kiln Shell Laser It measures continuously the distance to the shell and records the deviations. The tool is placed in various positions along the kiln. For evaluation, the shape of the kiln shell is displayed in line and radar charts as well in 3d.

52 Kiln Shell Laser Kiln Shell Laser on G-Clamp Kiln Shell Laser on Tripod Rotation Trigger Kiln Shell Laser in transport case Kiln Shell Laser

53 Kiln Shell Laser placed in various positions along the kiln Kiln Shell Laser

54 The Rotation Trigger synchronizes the Kiln Shell Laser with the kiln rotation It is attached to the girth gear and provides continuously the rotation position of the kiln via Bluetooth to the measurement computer

55 Kiln Shell Laser in the Measurement Studio offers different display options for evaluation Kiln Shell Laser

56 Telescopic Contact Thermometer To measure the shaft temperature of the support rollers It helps to evaluate the condition of the bearings and the thrust load The telescopic handle makes it easy to reach the roller shaft It is much more precise than pyrometers and not affected by the oil film

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